CN115335491A - Hydrocarbon pyrolysis of silicon-containing feedstock - Google Patents
Hydrocarbon pyrolysis of silicon-containing feedstock Download PDFInfo
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- CN115335491A CN115335491A CN202180025337.6A CN202180025337A CN115335491A CN 115335491 A CN115335491 A CN 115335491A CN 202180025337 A CN202180025337 A CN 202180025337A CN 115335491 A CN115335491 A CN 115335491A
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- steam
- steam cracker
- naphtha
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- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract description 250
- 229930195733 hydrocarbon Natural products 0.000 title claims abstract description 247
- 239000004215 Carbon black (E152) Substances 0.000 title claims abstract description 196
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 title claims description 129
- 239000010703 silicon Substances 0.000 title claims description 126
- 229910052710 silicon Inorganic materials 0.000 title claims description 125
- 238000000197 pyrolysis Methods 0.000 title description 75
- 239000002210 silicon-based material Substances 0.000 claims abstract description 122
- 238000000034 method Methods 0.000 claims abstract description 87
- 238000004230 steam cracking Methods 0.000 claims abstract description 75
- 239000003054 catalyst Substances 0.000 claims description 171
- 239000000203 mixture Substances 0.000 claims description 65
- 230000008569 process Effects 0.000 claims description 56
- 239000003921 oil Substances 0.000 claims description 41
- 239000007789 gas Substances 0.000 claims description 40
- 229920001296 polysiloxane Polymers 0.000 claims description 34
- 238000009835 boiling Methods 0.000 claims description 28
- 239000007791 liquid phase Substances 0.000 claims description 24
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 23
- 239000010779 crude oil Substances 0.000 claims description 20
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 17
- -1 lava Substances 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 14
- 230000009849 deactivation Effects 0.000 claims description 13
- 150000001993 dienes Chemical class 0.000 claims description 13
- 150000001336 alkenes Chemical class 0.000 claims description 11
- 239000012808 vapor phase Substances 0.000 claims description 11
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 9
- 239000005977 Ethylene Substances 0.000 claims description 9
- 150000005673 monoalkenes Chemical class 0.000 claims description 9
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 9
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 9
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 7
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 claims description 5
- 229910000037 hydrogen sulfide Inorganic materials 0.000 claims description 5
- WHDPTDWLEKQKKX-UHFFFAOYSA-N cobalt molybdenum Chemical compound [Co].[Co].[Mo] WHDPTDWLEKQKKX-UHFFFAOYSA-N 0.000 claims description 4
- DDTIGTPWGISMKL-UHFFFAOYSA-N molybdenum nickel Chemical compound [Ni].[Mo] DDTIGTPWGISMKL-UHFFFAOYSA-N 0.000 claims description 4
- 230000007420 reactivation Effects 0.000 claims description 4
- WWNBZGLDODTKEM-UHFFFAOYSA-N sulfanylidenenickel Chemical compound [Ni]=S WWNBZGLDODTKEM-UHFFFAOYSA-N 0.000 claims description 4
- 150000003464 sulfur compounds Chemical class 0.000 claims description 4
- 239000004927 clay Substances 0.000 claims description 3
- 238000009616 inductively coupled plasma Methods 0.000 claims description 3
- 238000004876 x-ray fluorescence Methods 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 2
- 239000008262 pumice Substances 0.000 claims description 2
- 239000010453 quartz Substances 0.000 claims description 2
- 239000004576 sand Substances 0.000 claims description 2
- 239000011874 heated mixture Substances 0.000 claims 7
- 238000005259 measurement Methods 0.000 claims 1
- 238000000926 separation method Methods 0.000 description 42
- 238000010791 quenching Methods 0.000 description 25
- 239000012530 fluid Substances 0.000 description 14
- 239000007788 liquid Substances 0.000 description 12
- 239000011269 tar Substances 0.000 description 12
- 238000005984 hydrogenation reaction Methods 0.000 description 10
- 239000000377 silicon dioxide Substances 0.000 description 10
- 239000008186 active pharmaceutical agent Substances 0.000 description 8
- 238000006243 chemical reaction Methods 0.000 description 8
- 238000005235 decoking Methods 0.000 description 8
- 230000005484 gravity Effects 0.000 description 8
- 229910021331 inorganic silicon compound Inorganic materials 0.000 description 8
- 150000003961 organosilicon compounds Chemical class 0.000 description 8
- 238000012545 processing Methods 0.000 description 7
- 125000004432 carbon atom Chemical group C* 0.000 description 6
- 238000006477 desulfuration reaction Methods 0.000 description 6
- 230000023556 desulfurization Effects 0.000 description 6
- 239000012071 phase Substances 0.000 description 6
- 230000000717 retained effect Effects 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 5
- 239000000356 contaminant Substances 0.000 description 5
- 229910052500 inorganic mineral Inorganic materials 0.000 description 5
- 239000011707 mineral Substances 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 4
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 4
- 150000001721 carbon Chemical group 0.000 description 4
- 238000005194 fractionation Methods 0.000 description 4
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 4
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical class [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 4
- 229910052717 sulfur Inorganic materials 0.000 description 4
- 239000011593 sulfur Substances 0.000 description 4
- 241000899793 Hypsophrys nicaraguensis Species 0.000 description 3
- 239000000571 coke Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 238000002354 inductively-coupled plasma atomic emission spectroscopy Methods 0.000 description 3
- 229930195734 saturated hydrocarbon Natural products 0.000 description 3
- 229910052604 silicate mineral Inorganic materials 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- 229910052645 tectosilicate Inorganic materials 0.000 description 3
- 238000011282 treatment Methods 0.000 description 3
- 229930195735 unsaturated hydrocarbon Natural products 0.000 description 3
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 2
- 238000004517 catalytic hydrocracking Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 2
- 239000003502 gasoline Substances 0.000 description 2
- 238000001095 inductively coupled plasma mass spectrometry Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000001294 propane Substances 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 238000010992 reflux Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 150000004760 silicates Chemical class 0.000 description 2
- 229910052814 silicon oxide Inorganic materials 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 238000009834 vaporization Methods 0.000 description 2
- 230000008016 vaporization Effects 0.000 description 2
- DJHGAFSJWGLOIV-UHFFFAOYSA-K Arsenate3- Chemical class [O-][As]([O-])([O-])=O DJHGAFSJWGLOIV-UHFFFAOYSA-K 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 239000011149 active material Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910021417 amorphous silicon Inorganic materials 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- GCPXMJHSNVMWNM-UHFFFAOYSA-N arsenous acid Chemical class O[As](O)O GCPXMJHSNVMWNM-UHFFFAOYSA-N 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 229910000175 cerite Inorganic materials 0.000 description 1
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical class [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 229910052607 cyclosilicate Inorganic materials 0.000 description 1
- 238000011033 desalting Methods 0.000 description 1
- IJKVHSBPTUYDLN-UHFFFAOYSA-N dihydroxy(oxo)silane Chemical compound O[Si](O)=O IJKVHSBPTUYDLN-UHFFFAOYSA-N 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 239000000539 dimer Substances 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 238000004821 distillation Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000013213 extrapolation Methods 0.000 description 1
- 239000003546 flue gas Substances 0.000 description 1
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- 229910001679 gibbsite Inorganic materials 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 229910052610 inosilicate Inorganic materials 0.000 description 1
- ICIWUVCWSCSTAQ-UHFFFAOYSA-N iodic acid Chemical class OI(=O)=O ICIWUVCWSCSTAQ-UHFFFAOYSA-N 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052605 nesosilicate Inorganic materials 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 229910052615 phyllosilicate Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000000066 reactive distillation Methods 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 230000003716 rejuvenation Effects 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- QYHFIVBSNOWOCQ-UHFFFAOYSA-N selenic acid Chemical class O[Se](O)(=O)=O QYHFIVBSNOWOCQ-UHFFFAOYSA-N 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 229910052606 sorosilicate Inorganic materials 0.000 description 1
- 229910052566 spinel group Inorganic materials 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical class [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- LSGOVYNHVSXFFJ-UHFFFAOYSA-N vanadate(3-) Chemical class [O-][V]([O-])([O-])=O LSGOVYNHVSXFFJ-UHFFFAOYSA-N 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G9/34—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts
- C10G9/36—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G45/32—Selective hydrogenation of the diolefin or acetylene compounds
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
- C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G69/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process
- C10G69/02—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only
- C10G69/06—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only including at least one step of thermal cracking in the absence of hydrogen
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/10—Feedstock materials
- C10G2300/1033—Oil well production fluids
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/20—Characteristics of the feedstock or the products
- C10G2300/201—Impurities
- C10G2300/202—Heteroatoms content, i.e. S, N, O, P
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/20—Characteristics of the feedstock or the products
- C10G2300/30—Physical properties of feedstocks or products
- C10G2300/301—Boiling range
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/02—Gasoline
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/20—C2-C4 olefins
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- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Silicon Compounds (AREA)
Abstract
A method and system for pyrolyzing a hydrocarbon feed for a predetermined period of time, such as by steam cracking. The method can include determining a first amount of silicon material present in a hydrocarbon feed to be steam cracked to produce a steam cracker effluent. The method can also include determining a second amount of silicon material to be present in steam cracker naphtha to be separated from the steam cracker effluent.
Description
Cross Reference to Related Applications
This application claims priority and benefit from U.S. provisional application No. 63/002,433, filed on 31/3/2020, and EP application No. 20184304.2, filed on 06/7/2020, the disclosures of both of which are incorporated herein by reference in their entireties.
Technical Field
Embodiments disclosed herein relate generally to compositions for C 5+ Pyrolysis processes for hydrocarbon conversion, for example conversion of heavy oils such as crude oil. More particularly, such processes relate to pyrolysis processes and systems for pyrolyzing a hydrocarbon feed containing one or more forms of silicon.
Background
Pyrolysis processes, such as steam cracking, convert lower value hydrocarbonaceous feeds into higher value products, such as ethylene and propylene. In addition, pyrolysis can produce naphtha, gas oils, and a number of lower value heavy products, such as pyrolysis tars.
When the steam cracker is operated in pyrolysis mode, the hydrocarbon feed is preheated and combined with steam in a tubular convection coil located in the convection section of the steam cracker furnace. The feed-steam mixture or a vapor portion thereof is pyrolyzed in tubular radiant coils located in the radiant section of a steam cracking furnace. During pyrolysis mode operation, separation equipment located downstream of the steam cracking furnace is typically used to separate various products from the steam cracker effluent, such as process gas, steam Cracker Naphtha (SCN), steam Cracker Gas Oil (SCGO), steam Cracker Quench Oil (SCQO), steam Cracker Tar (SCT), and the like. Because coke accumulates in locations within the steam cracking furnace, the furnace is typically switched from pyrolysis mode to decoking mode to remove the coke, for example, from the radiant coils. During the decoking mode, the flow of hydrocarbon feed to the steam cracking furnace is reduced or stopped, and instead a flow of decoking fluid is established. The decoking fluid typically contains one or more of steam, water, and air. In continuous decoking, the decoking fluid contains little or no air, and one portion of the radiant coils remains in pyrolysis mode while another portion of the radiant coils operates in decoking mode.
As the technology for pyrolyzing predominantly liquid phase hydrocarbon feeds improves, there is increasing interest in utilizing heavier liquid phase feeds, such as those predominantly liquid phase hydrocarbon feeds having an API gravity less than that of naphtha ("heavier predominantly liquid phase hydrocarbon feeds," also referred to as "advantageous feeds"). While advantageous feeds may include those that have undergone prior processing, such as certain gas oils, advantageous feeds may also include feedstocks, such as crude oils, for example, crude oils containing medium hydrocarbons (medium hydrocarbons) and/or heavy hydrocarbons. For example, utilizing advantageous feeds including raw feedstocks (e.g., various crude oils) will increase the supply of available liquid feeds and will reduce the dependence of steam cracker facilities on refinery process streams to meet steam cracker feed requirements. This in turn will improve steam cracker plant economics, for example by reducing light olefin production costs and by making higher value refinery streams available for other purposes.
Although heavier hydrocarbon feeds have become an attractive option, such feeds may introduce significant levels of contaminants, such as various forms of silicon-containing compositions, into the pyrolysis process, for example from a cost perspective, using higher value feedstocks, such as C 2 -C 4 Conventional pyrolysis processes for hydrocarbons are generally not a problem. The presence of silicon-containing materials can interfere with pyrolysis processes, particularly with the separation, recovery, and upgrading of certain pyrolysis products. This, in turn, may result in a shortened operating period of indeterminate duration, after which equipment and materials used in the pyrolysis process require repair, regeneration, or other recovery activities before the process can be put back into operation.
Accordingly, there is a need for improved pyrolysis processes, such as steam cracking, for pyrolyzing a hydrocarbon feed containing one or more silicon-containing contaminants. There is a particular need for a process and system that is capable of pyrolyzing a hydrocarbon feed containing one or more forms of a silicon-containing composition and recovering the desired products from the pyrolysis effluent for a predetermined period of time.
Disclosure of Invention
Summary of The Invention
The present invention is based in part on the following findings: pyrolysis converts at least a portion of certain forms of silicon (e.g., elemental silicon and/or silicon dioxide) present in the hydrocarbon feed to other forms of silicon-containing compositions, such as silicones (silicones) that occur in the pyrolysis effluent. In addition to the silicones resulting from the conversion, it has also been found that unconverted silicones can also be present in the pyrolysis effluent, such as silicones that are present in the hydrocarbon feed and carried over via pyrolysis. It has been observed that the presence of certain forms of silicon (e.g., silicone produced by or carried over by pyrolysis) can result in difficult processing of the pyrolysis effluent. More specifically, it has been found that certain forms of silicon (e.g., silicones) having atmospheric boiling points in the naphtha boiling range can be used to deactivate the catalyst used to hydrotreat the naphtha boiling range fraction of the pyrolysis effluent, resulting in a shortened operating length of the hydrotreating reactor. This in turn limits the duration of the period during which pyrolysis can be operated. After the hydroprocessing catalyst has been replaced, regenerated, rejuvenated or otherwise restored, pyrolysis can be returned to operation.
Accordingly, certain aspects of the present invention relate to processes, methods, apparatuses, and systems for pyrolyzing a hydrocarbon feed containing one or more forms of a silicon-containing composition for a predetermined period of time. In these and other aspects, the type and amount of various silicon-containing compositions in the hydrocarbon feed ("feed compositional information") may be determined. It was observed that compositional information of the hydrocarbon feed can be used to determine the type and amount of the siliceous composition of the naphtha boiling range fraction produced by pyrolysis or carried over to the pyrolysis effluent via pyrolysis ("naphtha compositional information") for various hydrocarbon feeds. The naphtha composition information can be used to preselect the amount of hydrotreating catalyst so that hydrotreating of the naphtha fraction of the pyrolysis effluent can be carried out over a predetermined period of time without the need to replace, regenerate, and/or rejuvenate the catalyst or otherwise restore the activity of the catalyst (collectively "replace or reactivate").
In aspects in which pyrolysis includes steam cracking, a hydrocarbon feed and an aqueous composition comprising water, steam, or a mixture of water and steam can be mixed and heated (in any order) to produce a steam cracked feed. Gas phase products and liquid phase products can be separated from the steam cracking feed. The vapor phase products (referred to herein as pyrolysis feed) can be steam cracked to produce a steam cracker effluent. Steam cracker naphtha and process gases which may comprise ethylene and propylene may be separated from the steam cracker effluent. The steam cracker naphtha may be hydrotreated for at least a predetermined period of time.
Steam cracking may include measuring a first amount of silicon in the hydrocarbon feed. Said first amount of silicon is equal to the total mass of silicon present in the form of all silicon in a given mass of hydrocarbon feed. The second amount of silicon to be present in the steam cracker naphtha to be separated from the steam cracker effluent may be determined based at least in part on the first amount of silicon. Said second amount of silicon is equal to the total mass of silicon present in all silicon forms in a given amount of steam cracker naphtha. A sufficient amount of at least one catalyst can be introduced into the hydrotreating unit to allow the hydrotreating unit to hydrotreat the steam cracker naphtha to be separated from the steam cracker effluent at least for a predetermined period of time without the need to replace or reactivate the at least partially deactivated catalyst, wherein the deactivation is caused by the second amount of silicon in the steam cracker naphtha.
Drawings
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 depicts a schematic diagram of an illustrative system for steam cracking a hydrocarbon feed, separating therefrom a product comprising steam cracker naphtha, and hydrotreating the steam cracker naphtha for at least a predetermined period of time, according to one or more embodiments.
FIG. 2 depicts a schematic diagram of another illustrative system for steam cracking a hydrocarbon feed, separating therefrom a product comprising steam cracker naphtha, and hydrotreating the steam cracker naphtha for at least a predetermined period of time, according to one or more embodiments.
Detailed Description
It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures and/or functions of the invention. Exemplary embodiments of components, arrangements and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided as examples only and are not intended to limit the scope of the present invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and in the figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the figures. Furthermore, the exemplary embodiments provided below may be combined in any manner, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment without departing from the scope of the disclosure. For the purposes of this description and the appended claims, the following terms are defined.
"hydrocarbons" refers to a class of compounds containing carbon-bonded hydrogen. The term "C n "Hydrocarbon" means a hydrocarbon containing n carbon atoms per molecule, where n is a positive integer. The term "C n+ "Hydrocarbon" means a hydrocarbon containing at least n carbon atoms per molecule, where n is a positive integer. The term "C n- "Hydrocarbon" means a hydrocarbon containing up to n carbon atoms per molecule, where n is a positive integer. "hydrocarbons" encompasses (i) saturated hydrocarbons, (ii) unsaturated hydrocarbons, and (iii) mixtures of hydrocarbons, including mixtures of hydrocarbon compounds (saturated and/or unsaturated), including mixtures of hydrocarbon compounds having different values of n.
By "heavy hydrocarbon" is meant a mixture comprising hydrocarbons having an API gravity in the range of from 5 ° to (but not including) 22 °. "Medium hydrocarbon" refers to a mixture comprising hydrocarbons having an API gravity in the range of 22 ° to 30 °. The "heavier" hydrocarbons have a smaller API gravity than the naphtha.
The term "unsaturated" or "unsaturated hydrocarbon" refers to a C containing at least one carbon atom directly bonded to another carbon atom through a double or triple bond 2+ A hydrocarbon. The term "olefin" refers to an unsaturated hydrocarbon containing at least one carbon atom directly bonded to another carbon atom through a double bond. In other words, an olefin is a compound containing at least one pair of carbon atoms, wherein the first and second carbon atoms of the pair are directly connected by a double bond. "light olefins" means C 5- An olefin.
By "predominantly liquid phase" is meant a composition in which 50% by weight or more, such as 75% by weight or more, such as 90% by weight or more, is in the liquid phase. When 50 wt.% or more of the hydrocarbon feedstock is in the liquid phase at a temperature of 25 ℃ and a pressure of 1 bar absolute (e.g.. Gtoreq.75 wt.%, such as. Gtoreq.90 wt.%), the hydrocarbon feedstock is predominantly in the liquid phase.
"raw" feedstock, e.g., raw hydrocarbon feedstock, refers to a predominantly liquid phase feedstock comprising > 25 wt.% crude oil that has not undergone prior desalting and/or prior reflux fractionation treatment, e.g. > 50 wt.%, e.g. > 75 wt.%, or > 90 wt.%.
"crude oil" refers to a mixture comprising naturally occurring hydrocarbons of geological origin, wherein the mixture (i) comprises ≥ 1 wt.% residuum, e.g. ≥ 5 wt.%, e.g. ≥ 10 wt.%, and (ii) has an API gravity of ≤ 52 °, e.g. ≤ 30 °, e.g. ≤ 20 °, or ≤ 10 °, or ≤ 8 °. Crude oils may be classified by API gravity, for example heavy crude oils have an API gravity in the range of 5 ° to (but not including) 22 °.
The standard (or "atmospheric") boiling point and the standard boiling point range can be measured by gas chromatographic distillation according to the methods described in ASTM D-6352-98 or D2887, as by extrapolation for materials above 700 ℃.
Hydrocarbon feeds, e.g. C 5+ Hydrocarbons, such as those predominantly in the liquid phase at a temperature of 25 ℃ and a pressure of 1 bar (absolute), may be mixed, blended, combined, or otherwise mixed with an aqueous composition comprising water, steam, or mixtures thereofTo produce a steam cracked feed. The hydrocarbon feed can be heated before and/or after it is combined with the aqueous composition. A predominately gas-phase pyrolysis feed and liquid-phase products may be separated from the steam cracked feed. The pyrolysis feed can be heated and subjected to steam cracking conditions to produce a steam cracker effluent. The steam cracker effluent may be cooled to produce a cooled steam cracker effluent. For example, the steam cracker effluent can be directly contacted with a quench fluid and/or indirectly cooled via one or more heat exchangers (e.g., transfer line exchangers ("TLEs")) to produce a cooled steam cracker effluent. One of the products that can be separated from the cooled steam cracker effluent can be steam cracker naphtha. Steam cracker naphtha is C 5+ Hydrocarbons, e.g. C 5 -C 10+ A complex mixture of hydrocarbons having an initial atmospheric boiling point of from about 25 ℃ to about 50 ℃ and a final boiling point of from about 220 ℃ to about 265 ℃ as measured according to ASTM D2887-18. In some examples, the steam cracker naphtha can have an initial atmospheric boiling point of about 33 ℃ to about 43 ℃ and a final atmospheric boiling point of about 234 ℃ to about 244 ℃ as measured by ASTM D2887-18. The hydrocarbon feed contains one or more forms of silicon, such as silicon materials.
"silicon material" refers to a composition comprising silicon, such as a composition comprising one or more of elemental silicon, silicon oxides (including silicon dioxide). The term siliceous material encompasses both natural and synthetic forms of silicon, e.g., the siliceous material can be one or more of an aggregate, a mixture, an ore, a compound, a complex, and the like.
The steam cracker naphtha can be hydrotreated to produce a stabilized or hydrotreated steam cracker naphtha product. For example, the steam cracker naphtha can be hydrotreated in the presence of molecular hydrogen and one or more catalysts to produce a hydrotreated steam cracker naphtha, which can also be referred to as a stabilized steam cracker naphtha. Hydrotreating the steam cracker naphtha may hydrogenate at least a portion of any diolefins present in the steam cracker naphtha to mono-olefins and/or convert at least a portion of any olefins to paraffins (paraffins), and/or convert any sulfur to paraffins(s)At least a portion of the compounds are converted to hydrogen sulfide that may be present in the steam cracker naphtha. In some examples, motor gasoline ("mogas") blendstocks may be produced. The Mogas blendstock is a blend comprising C having an initial atmospheric boiling point of about 35 ℃ and a final boiling point of about 200 ℃ 4 -C 12 A mixture of hydrocarbons. The mogas blendstock can include stabilized steam cracker naphtha.
It has been surprisingly and unexpectedly discovered that hydrotreating steam cracker naphtha to produce hydrotreated steam cracker naphtha when the hydrocarbon feed contains silicon material can be a limiting factor in how long the steam cracking process can be run before the steam cracker needs to be shut down or shut down. More specifically, it has been found that one or more catalysts used in the hydrotreating of steam cracker naphtha may become deactivated, degraded, poisoned, or otherwise rendered insufficiently effective (collectively "deactivated") before rendering another processing unit ineffective for performing its processing function. It has been found that deactivation is primarily caused by silicon material in the hydrocarbon feed that is subjected to steam cracking and silicon material derived from silicon material in the hydrocarbon feed. The silicon material contained in the naphtha deactivates the catalyst(s) used in the hydrotreating of the steam cracker naphtha. Thus, a process and system for steam cracking a hydrocarbon feed containing high levels of silicon material (e.g., 0.05 parts per million by weight or "wppm" to about 50wppm silicon material or from about 0.1wppm to about 25wppm silicon material) can be configured to run for a predetermined period of time before shutdown or shutdown is required due to catalyst deactivation.
The predetermined period of time that the steam cracking process can be configured to operate can be any desired length of time as long as the hydroprocessing reactor has sufficient capacity for a predetermined amount of hydroprocessing catalyst(s). In some examples, the predetermined period of time may be from about 1 day, about 2 days, or about 3 days to about 1 month, about 6 months, about 1 year, about 1.5 years, about 2 years, about 3 years, or about 4 years. In some examples, the predetermined period of time may be based at least in part on a desired volume of hydrocarbon feed directed to the steam cracker for steam cracking during the predetermined period of time.
A method for upgrading or steam cracking a hydrocarbon feed for a predetermined period of time may include estimating, measuring, or otherwise determining a first amount of silicon, i.e., the amount of silicon present in the hydrocarbon feed in its various forms (e.g., the total mass (in grams) of all forms of silicon present in a given mass of hydrocarbon feed). The amount of silicon material in the hydrocarbon feed (and/or the amount of silicon in the silicon material) may be measured or otherwise determined using any suitable technique. In some examples, a representative sample of a hydrocarbon feed can be analyzed via an atomic emission detector, an x-ray fluorescence (XRF) spectrometer, an inductively coupled plasma mass spectrometer (ICP-MS), an inductively coupled plasma atomic emission spectroscopy (ICP-AES), or a combination thereof, to measure the amount of silicon material therein. The amount of Silicon material can be measured by inductively coupled plasma mass spectrometry according to UOP1006-14, trace Silicon in Petroleum Liquids by ICP-MS, ASTM International, west Conshooken, PA, 2014. The amount of silicon material can be measured via inductively coupled plasma atomic emission spectrometry according to ASTM D5708-15. In some examples, the amount of silicon material can be measured via inductively coupled plasma mass spectrometry according to ASTM D8110-17.
In certain aspects, the hydrocarbon feed comprises (i) a silicon material and (ii) a heavy and/or medium hydrocarbon. These aspects will now be described in more detail. The invention is not limited in these respects and this description is not meant to exclude other aspects within the broader scope of the invention, such as those in which the hydrocarbon feed is a medium and/or light hydrocarbon.
Hydrocarbon feedstock
In certain aspects, the hydrocarbon feedstock comprises hydrocarbons and silicon materials. Those skilled in the art will appreciate that the term "hydrocarbon feed" is a convenient label, but does not mean that the feed contains only hydrocarbons. Although at least a portion of the silicon material of the hydrocarbon feed may be added to the hydrocarbon feed, typically most or even all of the silicon material should be present in the feed at the feed source. For example, the silicon material in the hydrocarbon feed can be a silicon material naturally occurring in certain heavy hydrocarbons, such as a silicon material naturally occurring in crude oil. In these and other aspects, the hydrocarbon can have a normal final boiling point of about 315 ℃ or greater, such as about 400 ℃ or greater, about 450 ℃ or greater, or about 500 ℃ or greater.
In certain aspects, the hydrocarbons of the feed can be higher molecular weight hydrocarbons, such as heavy hydrocarbons, such as those that are pyrolyzed during steam cracking to produce larger quantities of steam cracker naphtha (also known as pyrolysis gasoline), steam cracker gas oil ("SCGO"), and SCT. Heavy hydrocarbons may include one or more of the following: residuum (also referred to as resid or residuum), gas oil, heating oil, jet fuel, diesel, kerosene, coker naphtha, hydrocrackate, reformate, raffmate reformate, distillate, crude oil, atmospheric pipestill bottoms, vacuum pipestill streams including bottoms, condensate, heavy non-virgin hydrocarbon streams from refineries, vacuum gas oil, heavy gas oil, naphtha contaminated with crude oil, atmospheric residuum, heavy residuum, C 4 A/residual oil mixture, a naphtha oil residue mixture, a gas oil residue mixture, a low sulfur waxy residual, an atmospheric residual, and a heavy residual.
In certain aspects, the hydrocarbon feed comprises economically advantageous, minimally processed heavy hydrocarbons containing non-volatile components and coke precursors. For example, the hydrocarbon feed may comprise about 1 wt% or more of heavy hydrocarbons, such as about 25 wt% or more, about 50 wt% or more, about 75 wt% or more, about 90 wt% or more, or about 99 wt% or more, based on the weight of the hydrocarbon feed. The hydrocarbon feed can comprise, consist of, or consist essentially of one or more feedstocks, such as one or more crude oils.
In certain aspects, the hydrocarbon feed also comprises lower molecular weight hydrocarbons (e.g., medium and/or light hydrocarbons). Light hydrocarbons typically include naphtha boiling range hydrocarbons and substantially saturated hydrocarbon molecules having less than five carbon atoms, such as ethane, propane, and mixtures thereof. Although hydrocarbon feedstocks containing light hydrocarbons generally produce higher yields of C than hydrocarbon feedstocks containing heavy hydrocarbons 2 Unsaturates, but heavy hydrocarbons are receiving increasing attention due to lower cost and higher availability.
In these and other aspects, silicon materials (natural and/or synthetic) may be present in the hydrocarbon feed. For example, the hydrocarbon feed may include one or more of silicon, a silicon-containing compound, and a composition comprising silicon and/or a silicon-containing compound. Such silicon-containing compounds include inorganic silicon compounds and/or organosilicon compounds. Illustrative inorganic silicon compounds can be or include, but are not limited to, silica, one or more silicates, or any mixture thereof. Illustrative organosilicon compounds can be or include, but are not limited to, silicones also known as polysiloxanes. In some examples, the polysiloxane can be or include, but is not limited to, a polysiloxane of the formula CH 3 [SiO] n CH 3 Of one or more polymethylsiloxanes of the formula (CH) 3 ) 3 SiO[(CH 3 ) 2 SiO] n Si(CH 3 ) 3 Or a mixture thereof. The natural and/or synthetic silicon material that may be found in the hydrocarbon feed may be or include one of the following, or one or more of the following: sand; clay; other siliceous compositions in the form of earthy and/or mineral matter (e.g., earthy aggregates such as rocks, stones, clay (dirt), etc.); quartz; glass; lava (lava); soapstone and pumice (pumce).
In certain aspects, the hydrocarbon feed contains silicon included in natural and/or synthetic minerals, such as one or more forms of silicate and/or non-silicate minerals, including compositions containing natural and/or synthetic silicon-containing minerals. For example, the hydrocarbon feed may contain natural and/or synthetic silicates, such as nesosilicates, sorosilicates, cyclosilicates, inosilicates (both single and multiple), phyllosilicates, tectosilicates (including with and without zeolite H), tectosilicates (both single and multiple), and tectosilicates (both single and multiple) 2 O) and silicon substituted germanates. Alternatively or additionally, the hydrocarbon feed may contain silicon in the form of natural and/or synthetic non-silicate minerals. Typical silicon-containing, non-silicate minerals include one or more of those metals, alloys, carbides, silicides, nitrides and/or phosphides containing silicon in any form, such as silicon carbide; comprisesOne or more of those halides, oxyhalides, and hydroxyhalides of silicon in any form, such as, for example, kenyaite (chukhovite); one or more of those oxides and hydroxides containing silicon in any form, vanadates, arsenites, antimonates, bismuthats, sulfites and iodates, for example one or more silicon-containing spinels such as gibbsite (tegsgrenite); one or more of those carbonates and nitrates that contain silicon in any form, such as, for example, titanosilicate cerite (tundrite); one or more of those sulfates, selenates, chromates, molybdates, tungstates, niobates containing silicon in any form, such as, for example, carbomite (dugganite); one or more of those phosphates, arsenates, polyvanadates containing silicon in any form, e.g. vanadomethate ((Ca, na) 3 Mn 2+ (V 5+ ,As 5+ ,Si) 3 O 12 ) (ii) a An amorphous silicon-containing mineral; and organic silicon-containing minerals.
At least a portion of the silicon in the hydrocarbon feed (in all forms) is present in the pyrolysis feed. For example, 10 wt% or more of the silicon present in the hydrocarbon feed (in all forms thereof) (based on the weight of the feed) is typically present in the pyrolysis feed, such as 25 wt% or more, or 50 wt% or more, or 75 wt% or more, or 90 wt% or more, or in the range of 5 wt% to 95 wt%, or 10 wt% to 90 wt%. Because there is typically little, if any, conversion of one form or silicon to another form in the steam cracking furnace at a location upstream of the radiant coil, 10 wt.% or more of the silicon material present in the hydrocarbon feed (based on the weight of the feed) is typically present in the pyrolysis feed, such as 25 wt.% or more, 50 wt.% or more, 75 wt.% or more, 90 wt.% or more, or in the range of 5 wt.% to 95 wt.%, or 10 wt.% to 90 wt.%. As will be appreciated by those skilled in the art, the amount of silicon material in the hydrocarbon feed present in the pyrolysis feed will depend on, for example, whether a gas-liquid separator is used to separate the pyrolysis feed from the steam cracked feed, and if so, on the fractionation point established for the gas-liquid separator.
Steam cracking pyrolysis feed under steam cracking process conditions typically results in the conversion of at least a portion of some forms of silicon in the pyrolysis feed to other forms of silicon. For example, steam cracking may result in the conversion of at least a portion of any polysiloxanes in the hydrocarbon feed and/or pyrolysis feed to other forms of smaller molecular weight silicone, such as linear and/or cyclic polysiloxanes. While the amount of each of the various forms of silicon may increase or decrease due to steam cracking, the total mass of silicon (in all forms) in the steam cracker effluent is typically substantially the same as the total mass of silicon (in all forms) in the pyrolysis feed. Thus, the silicon material in the steam cracker naphtha may correspond to the silicon material present in the hydrocarbon feed prior to steam cracking and/or the silicon material produced during steam cracking of the hydrocarbons. Those skilled in the art will appreciate that certain forms of steam cracker equipment, such as steam cracker tubes, for example certain forms of radiant coils, contain silicon material which can be transferred in small amounts into the steam cracker effluent during the pyrolysis mode and the continuous decoking mode. Typically, however, the amount of such transported silicon material in the steam cracker effluent is ≦ 1 wt%, based on the weight of the steam cracker effluent, such as ≦ 0.1 wt% or ≦ 0.01 wt%, such as in the range of 0.01 wt% to 1 wt%.
Since the amount of silicon material in the steam cracker effluent from other sources has been found to be small, the amount of silicon (in all forms) that may be present in the steam cracker naphtha fraction of the steam cracker effluent may be calculated or otherwise determined from the amount of silicon (in all forms) in the hydrocarbon feed. For example, the amount of silicon in the steam cracker effluent can be determined to an accuracy (on a weight basis) of 1% or better by multiplying the mass of silicon (found in all its forms) in the hydrocarbon feed by the mass of the hydrocarbon feed. During the pyrolysis mode, a first portion of the silicon material of the hydrocarbon feed may be removed from the process by a gas-liquid separation integrated with the convection section of the steam cracking furnace. When used, gas-liquid separation comprises separating at least two streams from the steam cracking feed: (i) A first stream comprising a major vapor portion of the steam cracking feed and (ii) a second stream comprising a major liquid portion of the steam cracking feed. In some examples, about 25% (by weight) of the silicon material in the hydrocarbon feed is transferred to the second stream, such as about 30%, for example about 35%, or about 40% to about 55%, or about 60%, or about 65%, about 70%, or about 75%. Thus, in some examples, about 25% (by weight) of the silicon material in the hydrocarbon feed is transferred into the first stream, such as about 30%, for example about 35%, or about 40% to about 55%, or about 60%, or about 65%, or about 70%, or about 75%. After optional additional heating, e.g., in the convection section of a steam cracking furnace, the first stream can be introduced as a pyrolysis feed into the radiant coils of one or more steam cracking furnaces.
In addition to steam cracker naphtha, various products may be separated from the cooled steam cracker effluent. Illustrative products that can be separated from the steam cracker naphtha can be or include, but are not limited to, process gases comprising ethylene and propylene, steam cracker gas oils, steam cracker quench oils, and steam cracker tar or tar products. Similar to steam cracker naphtha, steam cracker gas oil and steam cracker quench oil each comprise a mixture of compounds, primarily a mixture of hydrocarbon compounds. In some examples, at least a portion of the steam cracker quench oil may be mixed, blended, combined, or otherwise contacted with the steam cracker effluent to produce a cooled steam cracker effluent. It should be understood that there is typically an overlap in the composition and boiling point ranges between steam cracker naphtha and steam cracker gas oil. The final atmospheric boiling point of the steam cracker gas oil is typically from about 275 ℃ to about 285 ℃, measured according to ASTM D2887-18. It should also be understood that there is generally an overlap in composition and boiling point ranges between the steam cracker naphtha and the steam cracker quench oil. The final atmospheric boiling point of steam cracker quench oils is typically from about 455 ℃ to about 475 ℃, measured according to ASTM D2887-18. The steam cracker tar may have a final atmospheric boiling point of >650 ℃.
During the process of separating products from the cooled steam cracker effluent, a first portion of the silica material of the steam cracker effluent may be removed from the process as a component of the steam cracker naphtha, a second portion of the silica material may be removed from the process as a component of the steam cracker gas oil, and a third portion of the silica material may be removed from the process as a component of the tar product. In some examples, about 28 wt%, about 30 wt%, about 32 wt%, or about 34 wt% to about 36 wt%, about 38 wt%, about 40 wt%, or about 42 wt% of the silica material in the cooled steam cracker effluent may be removed from the process as a component of the steam cracker gas oil and/or tar product. In some examples, the steam cracker gas oil may also comprise silicon, for example from about 1 wt% to about 40 wt% of the silicon material in the cooled steam cracker quench oil.
The steam cracker naphtha contains a second amount of silicon, where the second amount of silicon is equal to the total mass of silicon present in all silicon forms in a given mass of steam cracker naphtha. The second amount may be about 5% to about 75%, such as about 10% to about 60%, such as about 15% to about 52.5%, or about 20% to about 50% of the first amount of silicon. Those skilled in the art will appreciate that the upper limit of these ranges may be utilized when determining the amount of hydrotreating catalyst needed to hydrotreat a steam cracker naphtha for a predetermined period of time. Thus, when the first amount of silicon is known, it can be determined or estimated that the predetermined amount of all forms of silicon in the steam cracker naphtha is about 75% of the first amount, such as about 60% of the first amount, such as about 52.5% of the first amount, or about 50% of the first amount.
Thus, certain aspects of the present invention are based, in part, on the discovery of how various forms of silicon in a hydrocarbon feed are distributed in a steam cracking process. Once the first amount of all forms of silicon in the hydrocarbon feed is measured, estimated, or otherwise determined, a second amount of all forms of silicon in the steam cracker naphtha can be determined for a specified steam cracking configuration and process conditions. And once the second amount of all forms of silicon in the steam cracker naphtha is determined, the amount of catalyst required for hydrotreating the naphtha can also be determined, for example, to run the steam cracking process for a predetermined period of time. In other words, the amount of catalyst required to (i) the amount and composition of the silicon material in the hydrocarbon feed and (ii) the one or more catalyst beds disposed within the one or more naphtha hydrotreaters to allow the steam cracking process to operate for a predetermined period of time can be predetermined depending on the type and amount of the various forms of silicon that make up the silicon material in the hydrocarbon feed. A sufficient amount of catalyst may be loaded or otherwise disposed within the hydrotreater prior to initiating the steam cracking process to enable hydrotreating of the steam cracker naphtha for at least the predetermined period of time. Once a sufficient amount of catalyst is disposed within the hydrotreater, the hydrocarbon feed can be steam cracked and steam cracking can continue for a predetermined period of time without requiring a shutdown due to the silicon material in the steam cracker naphtha.
The amount of catalyst disposed within the hydrotreater can be sufficient to allow one or more forms of silicon to accumulate on the catalyst in an amount of silicon (total silicon included in all forms of silicon present on the catalyst) of about 0.3 wt%, about 0.5 wt%, about 1 wt%, about 2 wt%, or about 3 wt% to about 5 wt%, about 10 wt%, or about 15 wt% or more based on the weight of the catalyst. It is to be understood that the weight of the catalyst includes the catalytically active components and any optional support materials and/or other optional components that are not catalytically active, at least in the context of the hydroprocessing that a given catalyst may optionally include. The amount of silicon material that a given catalyst can accommodate can depend, at least in part, on the particular catalyst and/or the particular processing conditions within the hydrotreater.
After determining the second amount of silicon in the steam cracker naphtha and typically also the amount of silicon material in the steam cracker naphtha (on a weight basis), one skilled in the art can readily calculate or otherwise determine the amount of catalyst that needs to be disposed within the one or more hydrotreaters to run the steam cracking process for a predetermined period of time. For any given amount of the various forms of silicon in the steam cracker naphtha, the amount of catalyst that should be disposed within the one or more hydrotreaters can depend at least in part on the particular catalyst, the mass flow rate of the steam cracker naphtha through the one or more hydrotreaters, the predetermined period of time, and/or the hydrotreating conditions within the one or more hydrotreaters. Properties that may be considered with respect to a particular catalyst may include, but are not limited to, the surface area of the catalyst, the pore volume of the catalyst, the pore size of the catalyst, the catalyst particle size, and/or the type and amount of catalytically active material in the catalyst. Hydroprocessing conditions that may be considered may include, but are not limited to, for example, temperature, pressure, hydrogen partial pressure, and/or weight hourly space velocity.
In some examples, the silicon material in the steam cracker naphtha can include about 0.01 wt%, about 0.05 wt%, about 0.1 wt%, or about 0.2 wt% to about 0.5 wt%, about 0.7 wt%, or about 1 wt% C 5 -C 6 Silicone, about 10 wt%, about 15 wt%, or about 20 wt% to about 30 wt%, about 35 wt%, or about 50 wt% of C 7 -C 9 A silicone, and about 60 wt%, about 65 wt%, or about 70 wt% to about 80 wt%, about 85 wt%, or about 90 wt% of C 10+ Silicones, based on the weight of silicon materials in the steam cracker naphtha. In other examples, the silica material in the steam cracker naphtha can include ≦ 1 wt% C 5 -C 6 Silicone, about 10 wt% to about 50 wt% C 7 -C 9 Silicone and about 60% to about 90% by weight of C 10+ Silicones, based on the weight of silicon materials in the steam cracker naphtha.
It was observed for a variety of heavy hydrocarbon feeds that determining the amount of silicon material in the hydrocarbon feed (on a mass basis) also provides the amount of any organosilicon compound in the feed (on a mass basis) relative to the combined amount of any elemental silicon and any inorganic silicon compound in the feed (on a mass basis). In a specific example, if the amount of silicon material in the hydrocarbon feed is determined to be about 0.25wppm, the silicon material in the hydrocarbon feed consists of about 0.15wppm of the organosilicon compound and about 0.1wppm of the combined amount of the inorganic silicon compound and elemental silicon. This distribution of silicon material in the hydrocarbon feed in the combination of (i) the organosilicon compound and (ii) the inorganic silicon compound and elemental silicon is observed for a wide range of wppm of silicon material in various heavy hydrocarbon feeds and hydrocarbon feeds, such as in the range of from about 0.01wppm to about 1wppm, such as from 0.05wppm to 0.5 wppm. From these values, one skilled in the art can easily estimate the first amount of silicon in the hydrocarbon feed from the amount of silicon material in the hydrocarbon feed.
It was also observed for a variety of heavy hydrocarbon feeds that determining the amount of silicon material in the hydrocarbon feed (on a mass basis) also provided the relative amounts of elemental silicon, inorganic silicon compound, and organosilicon compound relative to each other (on a mass basis). In one specific example, if the total amount of silicon material in the hydrocarbon feed (on a mass basis) is determined to be about 0.2wppm, the relative amounts of the various forms of silicon material are present in the following amounts (on a mass basis): about 0.1wppm of inorganic silicon compounds, about 0.08wppm of organosilicon compounds and about 0.02wppm of elemental silicon. This distribution of silicon material in the hydrocarbon feed in (i) the inorganic silicon compound, (ii) the organosilicon compound, and (iii) elemental silicon is observed for a wide range of wppm of silicon material in various heavy hydrocarbon feeds and hydrocarbon feeds, for example in the range of from about 0.01wppm to about 1wppm, for example from 0.05wppm to 0.5 wppm. From these values, one skilled in the art can readily determine the first amount of silicon in the hydrocarbon feed. From these values, one skilled in the art can readily make improved estimates of the first amount of silicon in the hydrocarbon feed based on the amount of silicon material in the hydrocarbon feed.
The steam cracker naphtha may be subjected to hydrotreating conditions to produce a hydrotreated steam cracker naphtha. Steam cracker naphthas typically contain various forms of silicon. Silicon present in these various forms typically includes at least a portion of the silicon present in the various forms in the hydrocarbon feed. Hydrotreating can be carried out in one or more hydrotreating stages under hydroconversion conditions, which can be independently selected for each stage, for example under conditions for performing one or more of pretreatment, hydrocracking (including selective hydrocracking), hydrogenation, hydrotreating, hydrodesulfurization, hydrodenitrogenation, hydrodemetallization, hydrodearomatization, hydroisomerization, or hydrodewaxing of the tar product, as the case may be. In some examples, steam cracker naphtha can be hydrotreated in one or more hydrotreating units, which may include one or more hydrotreating vessels or zones. The hydroprocessing vessel or zone can include one or more disposed thereinAnd (3) a catalyst. The catalyst may be in the form of a fixed catalyst bed, a circulating or slurry bed, or any other configuration. In some examples, the steam cracker naphtha may be subjected to one or more separation processes to, for example, remove at least a portion of any water and/or steam and/or remove any C prior to being subjected to hydrotreating 4 And at least a portion of the lighter hydrocarbons.
In some examples, steam cracker naphtha hydrotreating conditions can include a temperature of about 40 ℃, about 75 ℃, or about 100 ℃ to about 200 ℃, about 300 ℃, or about 370 ℃. In some examples, steam cracker naphtha hydrotreating conditions may be carried out at an absolute pressure of about 600kPa, about 1,000kpa, or about 1,500kpa to about 2,000kpa, about 2,750kpa, or about 4,000kpa. In some examples, steam cracker naphtha hydrotreating conditions can be about 1h -1 About 3h -1 Or about 5h -1 To about 8h -1 About 12h -1 Or about 15h -1 At a Weight Hourly Space Velocity (WHSV). In at least one example, the steam cracker naphtha hydrotreating conditions can include a temperature of about 40 ℃ to about 370 ℃, an absolute pressure of about 600kPa to about 4,000kPa, and about 1h -1 To about 15h -1 Catalyst Weight Hourly Space Velocity (WHSV). Illustrative hydrotreaters useful for hydrotreating steam cracker naphtha and methods of operating the same can include U.S. Pat. nos. 8,894,844; and U.S. patent application nos.: 2016/0376511.
In some examples, hydrotreating a steam cracker naphtha can include hydrotreating a steam cracker naphtha under a first set of hydrotreating conditions to produce an intermediate or pretreated steam cracker naphtha. The pretreated steam cracker naphtha can be hydrotreated under a second set of hydrotreating conditions to produce a hydrotreated steam cracker naphtha. In certain aspects, the first hydroprocessing conditions are substantially the same as the second hydroprocessing conditions, but in other aspects they are different.
In some examples, the steam cracker naphtha can be hydrotreated in the presence of molecular hydrogen and a first catalyst under a first set of hydrotreating conditions to produce a pretreated steam cracker naphtha, and the pretreated steam cracker naphtha can be hydrotreated in the presence of molecular hydrogen and a second catalyst under a second set of hydrotreating conditions to produce a hydrotreated steam cracker naphtha. In certain aspects, the first catalyst is substantially the same as the second catalyst, but in other aspects the catalysts are different. In some examples, the first catalyst may be or include nickel. For example, the first catalyst may be or include nickel sulfide. In some examples, the second catalyst may be or include nickel, molybdenum, cobalt, alloys thereof, or mixtures or combinations thereof. In some examples, the second catalyst may be or include a nickel molybdenum catalyst and/or a cobalt molybdenum catalyst.
In some examples, the amount of first catalyst that the steam cracker naphtha can contact during the first hydrotreating can be greater than the amount of second catalyst that the pretreated steam cracker naphtha can contact during the second hydrotreating. In other examples, the amount of first catalyst that the steam cracker naphtha can contact during the first hydrotreating can be less than the amount of second catalyst that the pretreated steam cracker naphtha can contact during the second hydrotreating. In still other examples, the amount of first catalyst that the steam cracker naphtha can contact during the first hydrotreatment can be nearly the same as the amount of second catalyst that the pretreated steam cracker naphtha can contact during the second hydrotreatment.
In some examples, when the hydrotreated steam cracker naphtha includes two hydrotreating units, about 5 wt%, about 10 wt%, about 12 wt%, or about 15 wt% to about 20 wt%, about 25 wt%, about 30 wt%, about 35 wt%, or about 40 wt% of the silicon material in the steam cracker naphtha can be deposited, trapped, contained, retained, reacted, or otherwise disposed on the first catalyst, based on the total weight of the silicon material in the steam cracker naphtha. In some examples, about 60 wt%, about 65 wt%, or about 70 wt% to about 80 wt%, about 85 wt%, about 90 wt%, or about 95 wt% of the silicon material in the pretreated steam cracker naphtha can be deposited, trapped, contained, retained, reacted, or otherwise disposed on the second catalyst based on the total weight of the silicon material in the steam cracker naphtha. Typically, when the hydrotreated steam cracker naphtha includes two hydrotreating units, about 5 wt.%, about 10 wt.%, about 12 wt.%, or about 15 wt.% to about 20 wt.%, about 25 wt.%, about 30 wt.%, about 35 wt.%, or about 40 wt.% of the silicon derived from the silicon material in the steam cracker naphtha can be deposited, trapped, contained, retained, reacted, or otherwise disposed on the first catalyst, based on the total weight of silicon present in various forms in the steam cracker naphtha. For example, about 60 wt%, about 65 wt%, or about 70 wt% to about 80 wt%, about 85 wt%, about 90 wt%, or about 95 wt% of the silicon derived from the silica material in the pretreated steam cracker naphtha can be deposited, trapped, contained, retained, reacted, or otherwise disposed on the second catalyst based on the total weight of the silicon present in the steam cracker naphtha in various forms.
Once a sufficient amount of catalyst is introduced into the hydrotreating unit to allow the hydrotreating unit to hydrotreat the steam cracker naphtha that can be separated from the steam cracker effluent for at least a predetermined period of time, the steam cracking process can be started and the hydrocarbon feed can be steam cracked. For example, once a sufficient amount of the first catalyst is introduced into the first hydroprocessing unit and a sufficient amount of the second catalyst is introduced into the second hydroprocessing unit to cause the hydroprocessing unit to hydroprocess the steam cracker naphtha that is separable from the steam cracker effluent for at least a predetermined period of time, the steam cracking process can be initiated and the hydrocarbon feed can be steam cracked for at least the predetermined period of time without the need to replace or reactivate the first and second catalysts due to catalyst deactivation by silicon materials present in the steam cracker naphtha.
In some examples, when hydrotreating steam cracker naphtha includes hydrotreating under a first set of hydrotreating conditions to produce a pretreated steam cracker naphtha and hydrotreating under a second set of hydrotreating conditions to produce a hydrotreated steam cracker naphtha, the first catalyst and the second catalyst may become less effective, deactivated, or otherwise consumed when the same or different amounts of silicon materials are deposited, retained, contained, retained, reacted, or otherwise disposed on the first catalyst and the second catalyst. An increase in the pressure drop across the hydroprocessing reactor from inlet to outlet may be an indication that the catalyst is not effective. For example, an increase in the hydrotreating reactor pressure drop of 1.1 times (e.g., 1.2 times, or 1.5 times, or 1.75 times, or 2 times) the reactor pressure drop at the start of hydrotreating may indicate that the catalyst is not effective.
In some examples, if a first set of hydroprocessing conditions selectively hydrogenate dienes to mono-olefins (where optionally some hydrodesulfurization occurs) and a second set of hydroprocessing conditions selectively hydrosulfurize (where optionally some hydrogenation occurs), the first catalyst may become less effective, deactivated, or otherwise consumed when the first catalyst accumulates a first amount of silicon material and the second catalyst may become less effective, deactivated, or otherwise consumed when the second catalyst accumulates a second amount of silicon material. The first amount may be less than, equal to, or greater than the second amount. In some examples, when the first catalyst accumulates about 0.3 wt%, about 0.4 wt%, about 0.5 wt%, or about 0.6 wt% to about 0.7 wt%, about 0.8 wt%, about 0.9 wt%, about 1 wt%, about 1.1 wt%, about 1.2 wt%, about 1.3 wt%, about 1.4 wt%, or about 1.5 wt% of the silicon material (or silicon derived from the silicon material) disposed thereon, the first catalyst may become less effective, deactivated, or otherwise consumed, based on the weight of the catalyst. In this embodiment, it has also been found that when the catalyst accumulates about 2 wt.%, about 2.5 wt.%, about 3 wt.%, about 3.5 wt.%, about 4 wt.%, or about 5 wt.% to about 6 wt.%, about 7 wt.%, about 8 wt.%, about 9 wt.%, about 10 wt.%, about 11 wt.%, about 12 wt.%, about 13 wt.%, about 14 wt.%, or about 15 wt.% of the silicon material (or silicon derived from the silicon material) disposed thereon, the second catalyst may become less effective, deactivated, or consumed. It should be appreciated that developing a more robust catalyst may result in an increased amount of silicon material that may be disposed on the first catalyst and/or the second catalyst before the catalyst becomes insufficiently functional, deactivated, or otherwise consumed.
Certain aspects of the invention will now be described with reference to fig. 1, which includes a vapor-liquid separator integrated with the convection section of a steam cracking furnace. The present invention is not limited in these respects and the description should not be construed as excluding other aspects within the broader scope of the invention, such as aspects that do not include such a gas-liquid separator.
Fig. 1 schematically illustrates a system 100 for steam cracking a hydrocarbon feed in line 101, separating a product comprising steam cracker naphtha therefrom via line 131, and hydrotreating the steam cracker naphtha in line 131 for at least a predetermined period of time, in accordance with one or more aspects. The hydrocarbon feed (e.g., containing C) via line 101 can be 5+ A feed of hydrocarbons) and an aqueous stream comprising water, steam, or a mixture of water and steam via line 102 are mixed, blended, combined, or otherwise contacted to produce a steam cracked feed, which is conducted via line 103. In certain aspects, the hydrocarbon feed in line 101 is preheated in the convection section 106 of the furnace 105 before it is combined with the aqueous stream in line 102. In some examples, the hydrocarbon feed may be or include U.S. Pat. nos. 7,993,435;8,696,888;9,327,260;9,637,694;9,657,239; and 9,777,227; and p.c.t. patent application publication No. WO 2018/111574.
In certain aspects, the hydrocarbon feed is introduced to an inlet of at least one convection coil located in a convection section of the steam cracking furnace for preheating. Preheating of the hydrocarbon feed may include indirect contact of the feed in the convection section of the steam cracker with hot flue gas traveling upwardly from the radiant section of the furnace. Typically, the hydrocarbon feed is distributed among a plurality of convection coils. These may be in the form of a set of heat exchange tubes located within the convection section of the steam cracker. Typically, the amount of aqueous stream in the steam cracking feed in line 103 is ≧ 5 wt% based on the weight of the steam cracking feed, such as in the range of from about 10 wt% to about 90 wt% or from about 10 wt% to about 95 wt%. Typically, 90 wt% or more of the remainder of the steam cracked feed is preheated hydrocarbon feed, e.g., 95 wt% or more, e.g., 99 wt% or more. In certain aspects, the steam cracking feed has a weight ratio of steam to hydrocarbon feed of from about 0.1 to about 1, for example from about 0.2 to about 0.6.
The steam cracked feed in line 103 can be heated to a temperature of, for example, from about 200 ℃ to about 585 ℃ to produce a heated steam cracked feed. For example, the steam cracked feed in line 103 can be heated in the convection section 106 of the furnace 105 to produce a heated steam cracked feed via line 108.
The vapor phase product and the liquid phase product can be separated from the heated steam cracked feed by introducing the heated steam cracked feed via line 108 into one or more separators, such as one or more flash separators, of the "first separation stage" 110. The gas phase products via line 111 and the liquid phase products (pyrolysis feed) via line 112 can be carried away from the first separation stage 110. Although it is otherwise applicable, it is particularly suitable to utilize the first separation stage in the process when the hydrocarbon feed or preheated hydrocarbon feed contains about 0.1 wt% or more, for example about 5 wt% or more, asphaltenes based on the weight of the hydrocarbon feed. In some examples, the first separation stage 110 may be or include one or more of U.S. Pat. nos. 7,138,047;7,090,765;7,097,758;7,820,035;7,311,746;7,220,887;7,244,871;7,247,765;7,351,872;7,297,833;7,488,459;7,312,371;6,632,351;7,578,929 and 7,235,705. The first separation stage can be configured (e.g., by selecting a gas-liquid fractionation point) to remove from about 5 wt.% to 95 wt.% (or from about 25 wt.% to about 75 wt.%) of the silicon material in the hydrocarbon feed in line 101 as a component of the liquid phase bottoms stream via line 112. Thus, in some examples, about 5 wt% to about 95 wt% (or about 25 wt% to about 75 wt%) of the silicon material in the hydrocarbon feed in line 101 can be a component of the vapor phase product (pyrolysis feed) in line 111. The bottom stream can include, for example, (i) at least about 5 wt% of the total silicon content (silicon in all forms) of the hydrocarbon feed, and (ii) at least about 10 wt% of the asphaltenes in the hydrocarbon feed. Typically, 10 wt% or more of the total silicon content (of all forms of silicon) of the hydrocarbon feed is present in the bottom stream, such as 15 wt% or more, for example 20 wt% or more, or 25 wt% or more, or 30 wt% or more, or in the range of from about 5 wt% to 50 wt%, or from about 10 wt% to 30 wt%; while 75 wt.% or more of the remainder of the total silicon content of the hydrocarbon feed is present in the pyrolysis feed, e.g., 90 wt.% or more.
It has been found that the use of the first separation stage increases the variety of hydrocarbon feeds that can be introduced into the steam cracker with little pretreatment. For example, it has been found that steam cracking of a wide range of hydrocarbon feeds, including those containing one or more of > 50 wt.% (e.g. > 75 wt.% or > 90 wt.%) of medium hydrocarbons, heavy hydrocarbons, original medium hydrocarbons, desalted heavy hydrocarbons and/or desalted medium hydrocarbons, heavy and/or medium crude oils, desalted heavy crude oils and/or desalted medium crude oils, and the like, based on the weight of the hydrocarbon feed, is facilitated by a first separation stage having at least one flash separation vessel integrated with the convection section of the steam cracking furnace.
It has also been found that utilizing the first separation stage results in improved management of undesirable contaminants in the steam cracked feed, as gas phase contaminants (e.g., those transferred to the pyrolysis feed) can be maintained within predetermined limits. In certain aspects, the first separation stage is advantageously utilized to transfer 50 wt.% or more of any salts and particulates in the liquid phase portion of the steam cracking feed to the bottoms stream, such as 75 wt.% or more, such as 90 wt.% or more, or 99 wt.% or more. The composition of the hydrocarbon feed directed to the steam cracking furnace, the amount of hydrocarbon feed directed to the furnace, the amount of preheating of the hydrocarbon feed, the amount of dilution steam combined with the preheated hydrocarbon feed and any amount of heating of the steam cracking feed upstream of the first separation stage are typically selected to achieve vaporization of 2 wt.% or more, such as 5 wt.% or more, for example 10 wt.% or more, or 20 wt.% or more, or 50 wt.% or more, or 75 wt.% or more, or 90 wt.% or more, or 95 wt.% or more of the hydrocarbon portion of the steam cracking feed at the point where the steam cracking feed enters the separation vessel. For example, these selections may be made to achieve about 5 wt% to about 98 wt%, such as about 10 wt% to about 95 wt%, for example about 20 wt% to about 80 wt%, or about 25 wt% to about 75 wt% partial vaporization of the hydrocarbons of the steam cracking feed. Typically, 75 wt% or more of the remainder of the hydrocarbon portion of the steam cracking feed (the portion not in the vapor phase) is in the liquid phase, e.g., 90 wt% or more and 95 wt% or more.
The composition (and thus properties such as viscosity and API gravity) of the hydrocarbon portion of the steam cracking feed, the flow rate of the steam cracking feed (particularly the flow rate of the liquid portion of the steam cracking feed), and the type and amount of salt and/or particulate matter in these streams may be selected to achieve a predetermined amount of liquid phase of the steam cracking feed. For feeds exhibiting a smaller flow rate, in particular a smaller flow rate of the liquid phase portion, a larger amount of steam cracking feed in the liquid phase is indicated. This is typically the case when the hydrocarbon feed comprises more viscous, usually heavier, hydrocarbons. It is generally desirable to select these properties and conditions to maintain about 2% or more, for example about 5% or more, of the hydrocarbon portion of the steam cracking feed in the liquid phase on a weight basis at the point where the steam cracking feed enters the disengaging vessel.
The first separation stage may comprise at least one flash separation vessel operating at a temperature of from about 315 ℃ to about 510 ℃ and/or a pressure of from about 275kPa to about 1400kPa, for example a temperature of from about 430 ℃ to about 480 ℃ and/or a pressure of from about 700kPa to about 760 kPa. Depending on the composition of the hydrocarbon feed and the conditions used in the convection section and flash separation vessel, the various forms of sulfur present in the pyrolysis feed may differ from those of the hydrocarbon feed. The bottoms stream may be taken from the flash separation vessel, for example for storage and/or further processing. A silicon-depleted, predominantly vapor-phase pyrolysis feed is directed to the radiant section for pyrolysis. Optionally, the pyrolysis feed may be subjected to further heating in the convection section before it is introduced into the radiant section.
Those skilled in the art will appreciate that a wide range of pyrolysis conditions can be used, and the selection of particular pyrolysis conditions will depend on, for example, the composition of the hydrocarbon feed selected and the various products and co-products in the steam cracker effluentRelative amounts, e.g., relative amounts of ethylene and propylene. For example, pyrolysis conditions typically include heating the pyrolysis feed in the radiant coil to achieve a temperature of the radiant coil effluent (measured at the outlet of the radiant coil) of about 400 ℃ or more, e.g., about 400 ℃ to about 1100 ℃, a pressure of about 10kPa or more (measured at the outlet of the radiant coil), and a residence time in the radiant coil of about 0.01 seconds to 5 seconds. In certain aspects, such as those in which the hydrocarbon feed comprises crude oil or desalted crude oil, the pyrolysis conditions may include one or more of: (i) A temperature of about 760 ℃ or more, such as about 760 ℃ to about 1100 ℃, or about 790 ℃ to about 880 ℃, (ii) a pressure of about 50kPa or more, such as about 60kPa to about 500kPa, or about 90kPa to about 240 kPa; and/or (iii) a residence time of about 0.1 seconds to about 2 seconds. For hydrocarbon feeds containing lighter hydrocarbons, temperatures in the range of from about 760 ℃ to about 950 ℃ are typically used. The prescribed steam cracking conditions may be sufficient to convert at least a portion of the hydrocarbon molecules of the pyrolysis feed to C by pyrolysis 2+ Olefins and converts a portion of the sulfur of the pyrolysis feed to a lower molecular weight form.
In certain aspects, the pyrolysis feed in line 111 can be heated to a temperature of ≧ 400 ℃, such as a temperature of about 425 ℃ to about 825 ℃, and introduced into the radiant section 107 of the furnace 105 to produce a steam cracker effluent that can be carried away via line 113. In some examples, the gas-phase product in line 111 can be heated in the convection section 106 of the furnace 105 prior to introducing the gas-phase product into the radiant section 107 of the furnace 105. In some examples, additional water and/or steam may be mixed, blended, combined, or otherwise contacted with the pyrolysis feed and then introduced into the radiant section 107 of the furnace 105 for pyrolysis (steam cracking). In some examples, the pyrolysis feed in line 111 can be in accordance with U.S. Pat. nos. 6,419,885;7,993,435;9,637,694; and 9,777,227; U.S. patent application publication No. 2018/0170832; and p.c.t. patent application publication No. WO2018/111574, is steam cracked.
The steam cracker effluent typically comprises unconverted components of the pyrolysis feed and pyrolysis products. The pyrolysis product generally comprises C 2+ OlefinsMolecular hydrogen, acetylene, aromatic hydrocarbon, saturated hydrocarbon, C 3+ Diolefin, aldehyde, CO 2 Steam cracker tar and various forms of silicon. In some examples, the steam cracker effluent via line 113 can be introduced to one or more separators of the "second separation stage" 125. In other examples, the steam cracker effluent in line 113 can be mixed, blended, combined, or otherwise contacted with the quench fluid in line 127 to produce a cooled steam cracker effluent in line 120, which can be introduced into the second separation section 125. In some examples, the steam cracker effluent in line 113 can be at a temperature of 300 deg.C or more, 400 deg.C or more, 500 deg.C or more, 600 deg.C or more, or 700 deg.C or more, or 800 deg.C or more. In certain aspects, the maximum temperature of the steam cracker effluent in line 113 when initially contacted with the quench fluid in line 127 can be about 425 ℃ to 850 ℃, e.g., about 450 ℃ to about 800 ℃.
Those skilled in the art will appreciate that the amount of quench fluid contacted with the steam cracker effluent should be sufficient to cool the steam cracker effluent to facilitate separation of the desired products in the second separation stage 125 (e.g., primary fractionator). While the amount of quench fluid required to do so may vary significantly from facility to facility, the weight ratio of quench fluid to steam cracker effluent is typically from about 0.1 to about 10, for example from 0.5 to 5, for example from 1 to 4. In particular instances, the desired weight ratio may be determined, for example, by any one or more of a number of factors, such as the amount of steam cracker effluent to be cooled, the temperature of the steam cracker effluent at the quench location, the composition and thermodynamic properties (e.g., enthalpy, C) of the quench fluid and the steam cracker effluent P Etc.), the desired temperature of the quench fluid-steam cracker effluent mixture (i.e., cooled steam cracker effluent) at the primary fractionator inlet, etc. For example, in certain aspects, the cooled steam cracker effluent in line 120 can comprise the quench fluid in an amount of from about 5 wt.% to about 95 wt.%, from about 25 wt.% to about 90 wt.%, or about 50 wt.%, or about 80 wt.%, based on the weight of the cooled steam cracker effluent.
As shown in fig. 1, the steam cracker quench oil taken from the second separation stage 125 via line 127 can be contacted with the steam cracker effluent in line 113 to produce a cooled steam cracker effluent in line 120. In some examples, the steam cracker gas oil and/or one or more application fluid products via line 133 can be used instead of or in addition to using the steam cracker quench oil to cool the steam cracker effluent in line 113. Suitable application fluid products may include U.S. Pat. nos. 9,090,836;9,637,694; and 9,777,227; and those disclosed in p.c.t. patent application publication No. WO 2018/111574.
In some examples, multiple products may be recovered from the second separation stage 125. For example, the overhead or process gas via line 129, steam cracker naphtha via line 131, steam cracker gas oil via line 133, steam cracker quench oil via line 127, and/or tar product via line 135 can be carried away from the second separation stage 125. In some examples, products that can be separated from the process gas in line 129 can include, but are not limited to, tail gas, ethane, ethylene, propane, propylene, crude C 4 A hydrocarbon, or any combination thereof. The second separation stage 125 may be or include one or more fractionators, knock-out drums, combined quench and primary fractionators, compressors, contaminant removal units, e.g., CO 2 And/or H 2 An S removal unit, an acetylene converter, and the like.
In some examples, conventional separation equipment may be used to separate various products, such as steam cracker naphtha, from the cooled steam cracker effluent. Such as one or more flash drums, knock-out drums, fractionators, water quench towers, indirect condensers, and the like. In some examples, illustrative separation stages may include, for example, those disclosed in U.S. patent No. 8,083,931. In other examples, products that can be separated from the cooled steam cracker effluent (e.g., steam cracker naphtha) can be separated according to the methods and systems disclosed in U.S. patent application publication No. 2014/0357923.
In some examples, at least a portion of the steam cracker naphtha via line 131 and molecular hydrogen via line 132 can be introduced to the one or more hydrotreating units 155 to produce a hydrotreated steam cracker naphtha via line 163. The steam cracker naphtha can be hydrotreated in the presence of molecular hydrogen and one or more catalysts (e.g., catalyst bed 160) under hydrotreating conditions sufficient to produce a hydrotreated steam cracker naphtha that can be carried off via line 163. Hydrotreating steam cracker naphtha can convert one or more diolefins in the steam cracker naphtha to monoolefins, one or more olefins in the steam cracker naphtha to paraffins, one or more sulfur compounds in the steam cracker naphtha to hydrogen sulfide, and/or produce dimers.
The steam cracker naphtha recovered from the second separator 125 can be introduced via line 131 to a hydrotreater 155. Alternatively or additionally, the steam cracker naphtha can be treated prior to introduction to the hydrotreater 155. For example, steam cracker naphtha can include water, steam, and/or light hydrocarbons, such as C 4 A hydrocarbon. Thus, the steam cracker naphtha in line 131 can be introduced into one or more separation stages. In some examples, the steam cracker naphtha via line 131 can be introduced to one or more separators of a third separation stage configured to remove at least a portion of any water contained therein to produce a water-lean steam cracker naphtha that can be introduced to the steam cracker naphtha hydrotreater 155. In other examples, the steam cracker naphtha may be introduced into the one or more separators of the fourth separation stage to separate any C that may be contained therein 4 And at least a portion of the lighter hydrocarbons. Thus, in some examples, the steam cracker naphtha introduced via line 131 to the steam cracker hydrotreater 155 can be introduced directly from the second separation stage 125, or can undergo one or more additional separations or other treatments to produce a steam cracker that can be introduced into the steam cracker hydrotreater 155And (4) naphtha.
In some examples, the steam cracker naphtha in line 131 can be split or otherwise apportioned into multiple portions, such as a first steam cracker naphtha and a second steam cracker naphtha having substantially the same composition. The first steam cracker naphtha can be subjected to hydrotreating conditions to produce a hydrotreated steam cracker naphtha. The second steam cracker naphtha may be recycled to the second separation stage 125, for example as reflux. Separating steam cracker naphtha into two or more fractions, separating water from steam cracker naphtha, separating C from steam cracker naphtha 4 Options for hydrocarbons and/or their other treatments may include those disclosed in U.S. patent application publication No. 2016/0376511.
The steam cracker naphtha hydrotreating conditions in the hydrotreater 155 can include a temperature of about 40 ℃, about 75 ℃, or about 100 ℃ to about 200 ℃, about 300 ℃, or about 375 ℃. The steam cracker naphtha hydrotreating conditions in the hydrotreater 155 may be at an absolute pressure of about 600kPa, about 1,000kPa, or about 1,500kPa to about 2,000kPa, about 2,750kPa, or about 4,000kPa. The steam cracker naphtha hydrotreating conditions in the hydrotreater 155 can be about 1h -1 About 3h -1 Or about 5h -1 To about 8h -1 About 12h -1 Or about 15h -1 At a Weight Hourly Space Velocity (WHSV). In thatIn some examples, the steam cracker naphtha hydrotreating conditions in hydrotreater 155 include a temperature of about 40 ℃ to about 370 ℃, an absolute pressure of about 600kPa to about 4,000kpa, and about 1h -1 To about 15h -1 Catalyst Weight Hourly Space Velocity (WHSV). Illustrative hydrotreaters useful for hydrotreating steam cracker naphtha and methods of operating the same can include U.S. Pat. nos. 8,894,844; and U.S. patent application nos.: 2007/0170098; and 2016/0376511.
FIG. 2 depicts a schematic of another illustrative system 200 for steam cracking a hydrocarbon feed in line 101, separating therefrom a product comprising steam cracker naphtha via line 131, and hydrotreating the steam cracker naphtha in line 131 for at least a predetermined period of time, in accordance with one or more embodiments. System 200 may be similar to system 100. As shown, the system 200 can include one or more separators of the third separation stage 205 that can separate tar products from the cooled steam cracker effluent in line 120 via line 135 prior to introducing the cooled steam cracker effluent into the one or more separators of the "second separation stage" 225. More specifically, the cooled steam cracker effluent via line 120 can be introduced into the third separation stage 205 and the overhead via line 207 and tar product via line 209 can be carried away therefrom. The overhead via line 207 can be introduced to the second separation stage 225 and the process gas via line 129, the steam cracker naphtha via line 131, the steam cracker gas oil via line 133, and the steam cracker quench oil via line 227 can be carried away therefrom, as discussed and described above with reference to fig. 1. In some examples, the overhead in line 207 can be further cooled by mixing, blending, combining, or otherwise contacting the overhead with steam cracker quench oil via line 228. In other examples, in addition to or in lieu of contacting the overhead in line 207, the steam cracker quench oil via line 228, the steam cracker gas oil via line 133, a portion of the steam cracker naphtha via line 131, and/or one or more application fluids can be contacted with the overhead in line 207 to further cool the overhead.
The system 200 may also include a hydroprocessing unit 229, which may include two or more hydrotreaters (two shown, 230, 240). The steam cracker naphtha via line 131 and molecular hydrogen via line 132 can be introduced into the first hydrotreater 230. The steam cracker naphtha can be hydrotreated in the presence of molecular hydrogen and a first catalyst (e.g., first catalyst bed 235) to produce an intermediate or pretreated steam cracker naphtha that can be taken off via line 237. In some examples, first hydrotreater 230 can be operated under conditions that favor the hydrogenation of dienes to mono-olefins over hydrodesulfurization. The pretreated steam cracker naphtha via line 237 and molecular hydrogen via line 238 can be introduced to the second hydrotreater 240. In some examples, in addition to or instead of introducing molecular hydrogen via line 238, molecular hydrogen can be cascaded from the first hydrotreater 230 to the second hydrotreater 240 along with the pretreated steam cracker naphtha via line 237. The pretreated steam cracker naphtha can be hydrotreated in the presence of molecular hydrogen and a second catalyst (e.g., second catalyst bed 245) to produce a hydrotreated steam cracker naphtha that can be carried off via line 247. In some embodiments, second hydrotreater 240 can be operated under conditions that favor desulfurization of the hydrogenation product recovered from first hydrotreater 230 over hydrogenation of dienes to mono-olefins.
The steam cracker naphtha can be hydrotreated in a first hydrotreater 230 under first hydrotreating conditions, and the pretreated steam cracker naphtha can be hydrotreated in a second hydrotreater 240 under second hydrotreating conditions. The first hydrotreating conditions may be the same as or different from the second hydrotreating conditions.
In some examples, the first hydrotreating conditions in the first hydrotreater 230 can include a temperature of about 40 ℃, about 75 ℃, or about 100 ℃ to about 200 ℃, about 300 ℃, or about 375 ℃. First addingThe first hydrotreating conditions in the hydrotreater 230 may be carried out at an absolute pressure of about 600kPa, about 1,000kPa, or about 1,500kPa to about 2,000kPa, about 2,750kPa, or about 4,000kPa. The first hydrotreating conditions in the first hydrotreater 230 can be about 1h -1 About 3h -1 Or about 5h -1 To about 8h -1 About 12h -1 Or about 15h -1 At a Weight Hourly Space Velocity (WHSV).
In some examples, the second hydrotreating conditions in the second hydrotreater 240 can include a temperature of about 40 ℃, about 75 ℃, or about 100 ℃ to about 200 ℃, about 300 ℃, or about 375 ℃. The first hydrotreating conditions in the first hydrotreater 230 may be carried out at an absolute pressure of about 600kPa, about 1,000kPa, or about 1,500kPa to about 2,000kPa, about 2,750kPa, or about 4,000kPa. The first hydrotreating conditions in the first hydrotreater 230 can be about 1h -1 About 3h -1 Or about 5h -1 To about 8h -1 About 12h -1 Or about 15h -1 At a Weight Hourly Space Velocity (WHSV).
The first hydrotreating conditions may be the same as or different from the second hydrotreating conditions. In some examples, the first hydroprocessing conditions can be sufficient to promote hydrogenation of dienes to mono-olefins relative to desulfurization of steam cracker naphtha, and the second stage hydroprocessing conditions can be sufficient to promote desulfurization of pretreated steam cracker naphtha relative to hydrogenation of dienes. In other examples, the first hydrotreating conditions can be sufficient to promote desulfurization of the steam cracker naphtha relative to hydrogenation of dienes in the steam cracker naphtha, and the second stage hydrotreating conditions can be sufficient to promote hydrogenation of dienes in the pretreated steam cracker naphtha relative to desulfurization of the pretreated steam cracker naphtha. In some examples, the temperature within the first hydrotreater 230 can be lower than the temperature within the second hydrotreater 240. It is to be understood that hydrogenation and desulfurization can be carried out in the first hydrotreater and the second hydrotreater. In some examples, suitable hydrotreater and/or hydrotreating conditions for the first hydrotreater and/or the second hydrotreater can include those described in U.S. Pat. nos. 5,807,477;5,679,241;5,851,383;8,163,167;8,894,844; and U.S. patent application nos.: 2007/0170098; and 2016/0376511.
The first hydrotreater 230 and the second hydrotreater 240 can include any type of hydrotreater. Conventional hydrotreaters may be used, but the invention is not limited thereto. In some examples, first hydrotreater 230 and second hydrotreater 240 can be or include fixed bed reactors, such as downflow fixed bed reactors, expanded bed reactors (expanded bed reactors), reactive distillation columns, and/or other types of hydrotreaters.
Prior to cracking the hydrocarbon feed in the steam line 101 in the steam cracking systems 100 and 200, the amount of catalyst that needs to be disposed within the hydroprocessing units 155, 229 to allow the steam cracking systems 100 and 200 to operate for a predetermined period of time can be calculated or otherwise determined. As noted above, it has been surprisingly and unexpectedly discovered that if the hydrocarbon feed in line 101 comprises a silicon material, the silicon material can render the catalyst (e.g., catalyst beds 160, 235, 245) disposed within the hydroprocessing units 155, 229 insufficiently effective before the silicon material renders the other processing unit ineffective. Thus, the amount of catalyst that needs to be disposed within the catalyst beds 160, 235, 245 to allow the hydroprocessing units 155, 229 to operate for at least a predetermined period of time can be determined based at least in part on the amount of silicon material in the hydrocarbon feed in line 101. A sufficient amount of catalyst may be disposed in the catalyst beds 160, 235, 245 prior to cracking the hydrocarbon feed in the steam line 101 to enable the hydrotreating units 155, 229 to hydrotreat the steam cracker naphtha at least for a predetermined period of time before the catalyst becomes less effective and requires shutting down the steam cracking systems 100, 200 to regenerate and/or replace them.
Other aspects of the invention
In other aspects, the invention relates to methods, systems, and apparatus for hydrocarbon upgrading for a predetermined period of time. Hydrocarbon upgrading may include various processes for producing process effluent from one or more specified hydrocarbon feeds, such as thermal conversion processes, e.g., pyrolysis (including, e.g., steam cracking), catalytic conversion processes, and the like. These and other aspects may includeThe first amount of silicon (the total mass of silicon present in the hydrocarbon feed as all silicon) is measured. The second amount of silicon can be determined from the first amount of silicon, where the second amount of silicon is equal to the total mass of silicon present as all silicon in the naphtha boiling range stream separated from the process effluent. The second amount of silicon is predetermined by the first amount of silicon and optionally by conditions used in the hydrocarbon upgrading (e.g., unit configuration and/or process conditions). A sufficient amount of one or more catalysts can be introduced into the hydrotreating unit to allow the hydrotreating unit to hydrotreat the naphtha boiling range stream for at least a predetermined period of time without the need to replace or reactivate the one or more catalysts due to deactivation by silicon present in various forms in the naphtha boiling range stream. In these and other aspects, the naphtha boiling range stream can have an initial boiling point of from about 30 ° f (1.1 ℃) to about 500 ° f (260 ℃), for example from about 40 ° f (4.4 ℃) to about 450 ° f (232 ℃), or about mixed C 5 The boiling point of the hydrocarbon is to an atmospheric boiling point range of 430 ° f (221 ℃).
The invention also relates to systems, methods and apparatus for performing all or part of any of the pyrolysis, steam cracking, hydrocarbon upgrading and separation. For example, upgrading or predetermined periods of time of the hydrocarbon feed may include a steam cracker, a first separator, a second separator, and a hydrotreating unit. The steam cracker can be configured to combine and indirectly heat (in any order) an aqueous composition comprising water and/or steam and one or more of the indicated hydrocarbon feeds to produce a steam cracked feed. The pyrolysis feed comprising at least a vapor portion of the steam cracked feed may be separated from the steam cracked feed, for example, in one or more first separators, for example, in one or more vapor-liquid separators (e.g., one or more flash drums). The pyrolysis feed can be pyrolyzed in one or more radiant coils in a steam cracker furnace to produce a steam cracker effluent. The second separator can be configured to separate steam cracker naphtha and a process gas that can include ethylene and propylene from the steam cracker effluent. The hydroprocessing unit can include one or more catalysts disposed therein. The hydrotreating unit can be configured to hydrotreat the steam cracker naphtha in the presence of one or more catalysts and molecular hydrogen for at least a predetermined period of time without requiring replacement or reactivation of the one or more catalysts due to catalyst deactivation by one or more forms of silicon present in the steam cracker naphtha. In some examples, the amount of the one or more catalysts in the hydroprocessing unit can be determined according to a method. For example, a first amount of silicon material (and/or the amount of various forms of silicon) in a hydrocarbon feed may be measured. The first amount of silicon can be used to determine a second amount of silicon (and/or silicon material) in the steam cracker naphtha. The amount of the one or more catalysts that should be disposed in the hydroprocessing unit can be determined based at least in part on the second amount of silicon. By using the process configuration and the process conditions, an improved accuracy in determining the second amount of silicon may be achieved, for example by setting a predetermined fractionation point in the first and/or second separator.
In these and other aspects, the hydrocarbon may be or include, but is not limited to, naphtha, gas oil, vacuum gas oil, waxy resid, atmospheric resid, crude oil, or mixtures thereof. A hydrocarbon feed is steam cracked under steam cracking conditions to produce a steam cracker effluent. Separating steam cracker naphtha from the steam cracker effluent, wherein the steam cracker naphtha has a second amount of silicon equal to the total mass of silicon present in the steam cracker naphtha in the form of all silicon. The form of silicon present in the steam cracker naphtha may include: c of not more than 1% by weight 5 -C 6 Silicone, about 10% to about 50% by weight of C 7 -C 9 Silicone and about 60% to about 90% by weight of C 10+ Silicones, wherein weight percent is based on the total weight of all silicon forms present in the steam cracker naphtha. The steam cracker naphtha may be hydrotreated in a first hydrotreating unit for at least a predetermined period of time to produce a pretreated steam cracker naphtha. The pretreated steam cracker naphtha may be hydrotreated in a second hydrotreating unit for at least a predetermined period of time to produce a hydrotreated steam cracker naphtha.
A sufficient amount of the one or more first catalysts can be introduced into the first hydroprocessing unit to allow the first hydroprocessing unit to hydroprocess the steam cracker naphtha to be separated from the steam cracker effluent for at least a predetermined period of time without the need to replace or reactivate the one or more first catalysts due to catalyst deactivation by silicon present in the steam cracker naphtha in one or more forms. A sufficient amount of the one or more second catalysts can be introduced into the second hydroprocessing unit to allow the second hydroprocessing unit to hydroprocess the pretreated steam cracker naphtha to be recovered from the first hydroprocessing unit for at least a predetermined period of time without the need to replace or reactivate the one or more second catalysts due to catalyst deactivation by silicon present in the pretreated steam cracker naphtha in one or more forms.
Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It is understood that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are "about" or "approximately" indicative values and take into account experimental error and deviation as would be expected by one of ordinary skill in the art.
Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. In addition, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this invention and for all jurisdictions in which such incorporation is permitted.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
Claims (26)
1. A method of upgrading hydrocarbons for a predetermined period of time, comprising:
determining a first amount of silicon material present in a hydrocarbon feed to be steam cracked in a steam cracker to produce a steam cracker effluent; and
determining a second amount of silicon material to be present in a steam cracker naphtha to be separated from the steam cracker effluent for a predetermined period of time, the second amount of silicon material based at least in part on the first amount of silicon material present in the hydrocarbon feed to be steam cracked.
2. The method of claim 1, wherein the second amount of silicon material to be present in the steam cracker naphtha is from 5% to about 75% of the first amount of silicon material present in the hydrocarbon feed to be steam cracked.
3. The method of claim 2, wherein the second amount of silicon material to be present in the steam cracker naphtha is from about 15% to about 52.5% of the first amount of silicon material present in the hydrocarbon feed to be steam cracked.
4. The method of any one of claims 1 to 3, wherein the first amount of silicon material present in the hydrocarbons to be steam cracked is determined by one or more measurements using one or more of an atomic emission detector, an x-ray fluorescence spectrometer, and an inductively coupled plasma mass spectrometer.
5. The process of any of claims 1 to 4 wherein the silicon material in the steam cracker naphtha contains ≤ 1 wt.% C 5 -C 6 Silicone, about 10 wt% to about 50 wt% C 7 -C 9 Silicone and about 60% to about 90% by weight of C 10+ Silicones, based on the weight of silicon materials in the steam cracker naphtha.
6. The process of any of claims 1 to 5, wherein the silicon material present in the hydrocarbon feed to be steam cracked comprises sand, clay, quartz, glass, lava, pumice, polysiloxanes, water-soluble hydrophilic silicones, or mixtures thereof, and wherein the one or more catalysts comprises a nickel sulfide catalyst, a nickel molybdenum catalyst, a cobalt molybdenum catalyst, or mixtures thereof.
7. The process of any of claims 1 to 6, wherein the first amount of silicon material present in the hydrocarbon feed to be steam cracked is from about 0.1 ppm by weight to about 25 ppm by weight based on the weight of the hydrocarbon feed to be steam cracked.
8. The method of any one of claims 1 to 7, further comprising:
introducing one or more catalysts into a hydrotreating unit in sufficient amounts to allow the hydrotreating unit to hydrotreat a steam cracker naphtha to be separated from the steam cracker effluent at least for a predetermined period of time without requiring replacement or reactivation of the one or more catalysts due to catalyst deactivation by silicon materials present in the steam cracker naphtha; and
wherein the hydroprocessing unit comprises a first hydrotreater comprising a first catalyst disposed therein and a second hydrotreater comprising a second catalyst disposed therein, and wherein the amount of the first catalyst introduced into the first hydrotreater is less than the amount of the second catalyst introduced into the second hydrotreater.
9. The process of claim 8, wherein the hydroprocessing unit includes a first hydrotreater and a second hydrotreater, the first hydrotreater including a first catalyst disposed therein, the second hydrotreater including a second catalyst disposed therein, and wherein the amount of the first catalyst introduced into the first hydrotreater is greater than the amount of the second catalyst introduced into the second hydrotreater.
10. The method of claim 9, wherein the predetermined period of time is based at least in part on a desired volume of hydrocarbon feed to be steam cracked during the predetermined period of time.
11. A method of upgrading hydrocarbons for a predetermined period of time comprising:
measuring a first amount of silicon material in a hydrocarbon feed to be steam cracked in a steam cracker to produce a steam cracker effluent; and
determining a second amount of silicon material to be present in a steam cracker naphtha to be separated from the steam cracker effluent based at least in part on the first amount of silicon material present in the hydrocarbon feed to be steam cracked;
introducing a sufficient amount of one or more catalysts into the hydrotreating unit to allow the hydrotreating unit to hydrotreat the steam cracker naphtha to be separated from the steam cracker effluent at least for a predetermined period of time without the need to replace or reactivate the one or more catalysts due to catalyst deactivation by silicon materials present in the steam cracker naphtha; and
heating a mixture comprising a hydrocarbon feed to be steam cracked and water, steam or a mixture of water and steam to produce a heated mixture comprising steam and the hydrocarbon feed to be steam cracked;
separating vapor phase products and liquid phase products from the heated mixture comprising steam and hydrocarbon feed to be steam cracked;
steam cracking the vapor phase product to produce a steam cracker effluent;
separating the steam cracker naphtha and a process gas comprising ethylene and propylene from the steam cracker effluent; and
hydrotreating the steam cracker naphtha for at least the predetermined period of time.
12. The method of claim 11, wherein the one or more catalysts comprise a nickel sulfide catalyst, a nickel molybdenum catalyst, a cobalt molybdenum catalyst, or mixtures thereof.
13. The method of claim 11 or 12, wherein the second amount of silicon material to be present in the steam cracker naphtha is in a range of from about 5% to about 75% of the first amount of silicon-containing material present in the hydrocarbon feed to be steam cracked.
14. The method of any one of claims 11 to 13, wherein the second amount of silicon material to be present in the steam cracker naphtha is from about 15% to about 52.5% of the first amount of silicon material present in the hydrocarbon feed to be steam cracked.
15. The method of any of claims 11 to 14, wherein the first amount of silicon material present in the hydrocarbon feed to be steam cracked is from about 0.1 ppm by weight to about 25 ppm by weight based on the weight of the hydrocarbon feed to be steam cracked, and wherein the second amount of silicon material to be present in the steam cracker naphtha is from about 0.015 ppm by weight to about 13.125 ppm by weight.
16. The method of any of claims 11 to 15, wherein the silicon material in the steam cracker naphtha comprises ≤ 1 wt% C 5 -C 6 Silicone, about 10% to about 50% by weight of C 7 -C 9 Silicone and about 60% to about 90% by weight of C 10+ Silicone, based on the weight of silicon material in the steam cracker naphtha.
17. The method of any one of claims 11 to 16, wherein:
the hydroprocessing unit includes a first hydrotreater including a first catalyst disposed therein and a second hydrotreater including a second catalyst disposed therein,
the first hydrotreater converts the diolefins in the steam cracker naphtha to mono-olefins to produce a first hydrotreated naphtha,
the second hydrotreater converts olefins in the first hydrotreated naphtha to paraffins and converts sulfur compounds in the first hydrotreated naphtha to hydrogen sulfide to produce a second hydrotreated naphtha, and
the amount of the first catalyst introduced into the first hydrotreater is less than the amount of the second catalyst introduced into the second hydrotreater.
18. The method of any one of claims 11 to 17, wherein:
the hydroprocessing unit includes a first hydrotreater including a first catalyst disposed therein and a second hydrotreater including a second catalyst disposed therein,
the first hydrotreater converts the diolefins in the steam cracker naphtha to mono-olefins to produce a first hydrotreated naphtha,
the second hydrotreater converts olefins in the first hydrotreated naphtha to paraffins and converts sulfur compounds in the first hydrotreated naphtha to hydrogen sulfide to produce a second hydrotreated naphtha, and
the amount of the first catalyst introduced into the first hydrotreater is greater than the amount of the second catalyst introduced into the second hydrotreater.
19. The process of any of claims 11 to 18, wherein the hydrocarbon feed to be steam cracked comprises naphtha, gas oil, vacuum gas oil, waxy resid, atmospheric resid, crude oil, or mixtures thereof.
20. The process of any of claims 11 to 19 wherein the steam cracker naphtha comprises C 5 To C 10+ A mixture of hydrocarbons, and having an initial boiling point at atmospheric pressure of about 25 ℃ to about 50 ℃ and a final boiling point at atmospheric pressure of about 220 ℃ to about 265 ℃ as measured according to ASTM D2887-18.
21. A system for upgrading hydrocarbons for a predetermined period of time, comprising:
a steam cracker configured to indirectly heat a mixture comprising steam and a hydrocarbon feed to produce a heated mixture, and steam crack a vapor phase product separated from the heated mixture to produce a steam cracker effluent;
a first separator configured to separate a vapor phase product and a liquid phase product from the heated mixture;
a second separator configured to separate steam cracker naphtha and a process gas comprising ethylene and propylene from the steam cracker effluent; and
a hydrotreating unit comprising one or more catalysts disposed therein, and configured to hydrotreat the steam cracker naphtha in the presence of the one or more catalysts and molecular hydrogen for at least a predetermined period of time without requiring replacement or reactivation of the one or more catalysts due to catalyst deactivation by silicon materials present in the steam cracker naphtha, wherein the amount of the one or more catalysts in the hydrotreating unit is determined according to a method comprising:
measuring a first amount of silicon material present in the hydrocarbon feed;
determining a second amount of silicon material to be present in a steam cracker naphtha to be separated from the steam cracker effluent based at least in part on the first amount of silicon material present in the hydrocarbon feed; and
determining an amount of the one or more catalysts that should be disposed in the hydrotreating unit based at least in part on the second amount of silicon materials that will be present in a steam cracker naphtha that is to be separated from the steam cracker effluent.
22. The system of claim 21, wherein the first catalyst comprises a nickel sulfide catalyst, and wherein the second catalyst comprises a nickel molybdenum catalyst, a cobalt molybdenum catalyst, or a mixture thereof.
23. The system of claim 21 or 22, wherein the hydrotreating unit comprises a first hydrotreater comprising a first catalyst disposed therein and a second hydrotreater comprising a second catalyst disposed therein, wherein the first hydrotreater is configured to convert diolefins in the steam cracker naphtha to monoolefins in the presence of molecular hydrogen and the first catalyst to produce a first hydrotreated naphtha, and wherein the second hydrotreater is configured to convert olefins in the first hydrotreated naphtha to paraffins and convert sulfur compounds to hydrogen sulfide in the presence of molecular hydrogen and the second catalyst to produce a second hydrotreated naphtha.
24. The system of any one of claims 21 to 23, further comprising an atomic emission detector, an x-ray fluorescence spectrometer, an inductively coupled plasma mass spectrometer, or a combination thereof configured to measure a first amount of silicon material present in the hydrocarbon feed to be steam cracked.
25. A method of upgrading hydrocarbons for a predetermined period of time comprising:
measuring a first amount of silicon material in a hydrocarbon feed to be steam cracked in a steam cracker to produce a steam cracker effluent, wherein the hydrocarbon comprises naphtha, gas oil, vacuum gas oil, waxy resid, atmospheric resid, crude oil, or mixtures thereof; and
determining a second amount of silicon material to be present in a steam cracker naphtha to be separated from the steam cracker effluent based at least in part on the first amount of silicon material present in the hydrocarbon feed to be steam cracked.
26. The method of claim 25, further comprising:
introducing a sufficient amount of one or more first catalysts into a first hydroprocessing unit to allow the first hydroprocessing unit to hydroprocess a steam cracker naphtha to be separated from a steam cracker effluent for at least a predetermined period of time without requiring replacement or reactivation of the one or more first catalysts due to catalyst deactivation by silicon materials present in the steam cracker naphtha;
introducing a sufficient amount of one or more second catalysts into a second hydroprocessing unit to allow the second hydroprocessing unit to hydroprocess pretreated steam cracker naphtha to be recovered from the first hydroprocessing unit for at least a predetermined period of time without the need to replace or reactivate the one or more second catalysts due to catalyst deactivation by silicon materials present in the steam cracker naphtha;
heating a mixture comprising a hydrocarbon feed to be steam cracked and water, steam or a mixture of water and steam to produce a heated mixture comprising steam and the hydrocarbon feed;
separating a vapor phase product and a liquid phase product from a heated mixture comprising steam and the hydrocarbon feed;
steam cracking the vapor phase product to produce a steam cracker effluent;
separating the steam cracker naphtha and a process gas comprising ethylene and propylene from the steam cracker effluent, wherein the silicon material in the steam cracker naphtha comprises ≤ 1 wt% of C 5 -C 6 Silicone, about 10% to about 50% by weight of C 7 -C 9 Silicone and about 60% to about 90% by weight of C 10+ Silicones, based on the weight of silicon materials in the steam cracker naphtha;
hydrotreating the steam cracker naphtha in the first hydrotreating unit for at least a predetermined period of time to produce the pretreated steam cracker naphtha; and
hydrotreating the pretreated steam cracker naphtha in the second hydrotreating unit for at least a predetermined period of time to produce a hydrotreated steam cracker naphtha.
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| PCT/US2021/018550 WO2021202009A1 (en) | 2020-03-31 | 2021-02-18 | Hydrocarbon pyrolysis of feeds containing silicon |
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